US8231043B2 - Surgical stapling apparatus - Google Patents

Abstract

A surgical stapling apparatus is provided and includes a cartridge assembly defining a tissue contacting surface and a longitudinally extending elongate slot, an anvil assembly defining a tissue contacting surface, and a longitudinally extending elongate slot. A surgical buttress is releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor. A central knife blade is slidably disposable in the longitudinal extending elongate slot of the cartridge assembly and the anvil assembly, and a knife blade is supported in a distal end portion of at least one of the cartridge assembly and the anvil assembly. The distal knife blade is actuatable by the central knife blade upon an actuation of the central knife blade.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No. 12/342,400, filed Dec. 23, 2008 (now U.S. Pat. No. 8,011,555), which is a continuation-in-part of U.S. application Ser. No. 12/528,526, filed Aug. 25, 2009, which is a National Stage Application of PCT/US2008/002981 under 35USC §371(a) filed Mar. 5, 2008, which claims priority of U.S. Provisional Patent Application Ser. No. 60/905,566, filed Mar. 6, 2007, the disclosures of each of the above-identified applications are hereby incorporated by reference in their entirety.

BACKGROUND

1. Technical Field

The present disclosure relates to a surgical apparatus, e.g., a surgical stapling apparatus. More particularly, the present disclosure relates to a surgical stapling apparatus including a detachable surgical buttress and/or an endoscopic surgical stapling apparatus that includes a detachable surgical buttress for a loading unit, e.g., a single use loading unit (“SULU”) or disposable loading unit (“DLU”). For simplicity, hereinafter, SULU or DLU will be referred to as “DLU”, but it should be understood to include either or both a DLU or SULU.

2. Background of Related Art

Surgical devices wherein tissue is first grasped or clamped between opposing jaw structure and then joined by surgical fasteners are well known in the art. In some instruments a knife is provided to cut the tissue which has been joined by the fasteners. The fasteners are typically in the form of surgical staples but two part polymeric fasteners can also be utilized.

Instruments for this purpose can include two elongated jaw members which are respectively used to capture or clamp tissue. Typically, one of the jaw members carries a staple cartridge which houses a plurality of staples arranged in at least two lateral rows while the other jaw member has an anvil that defines a surface for forming the staple legs as the staples are driven from the staple cartridge. Generally, the stapling operation is effected by cam members that travel longitudinally through the staple cartridge, with the cam members acting upon staple pushers to sequentially eject the staples from the staple cartridge. A knife can travel between the staple rows to longitudinally cut and/or open the stapled tissue between the rows of staples. Such instruments are disclosed, for example, in U.S. Pat. No. 3,079,606 and U.S. Pat. No. 3,490,675.

A later stapler disclosed in U.S. Pat. No. 3,499,591 also applies a double row of staples on each side of the incision. This patent discloses a surgical stapler that has a disposable loading unit in which a cam member moves through an elongate guide path between two sets of staggered staple carrying grooves. Staple drive members are located within the grooves and are positioned in such a manner so as to be contacted by the longitudinally moving cam member to effect ejection of the staples from the staple cartridge of the disposable loading unit. Other examples of such staplers are disclosed in U.S. Pat. Nos. 4,429,695 and 5,065,929.

Each of the instruments described above is designed for use in conventional surgical procedures wherein surgeons have direct manual access to the operative site. However, in endoscopic or laparoscopic procedures, surgery is performed through a small incision or through a narrow cannula inserted through small entrance wounds in the skin. In order to address the specific needs of endoscopic and/or laparoscopic surgical procedures, endoscopic surgical stapling devices have been developed and are disclosed in, for example, U.S. Pat. No. 5,040,715 (Green, et al.); U.S. Pat. No. 5,307,976 (Olson, et al.); U.S. Pat. No. 5,312,023 (Green, et al.); U.S. Pat. No. 5,318,221 (Green, et al.); U.S. Pat. No. 5,326,013 (Green, et al.); U.S. Pat. No. 5,332,142 (Robinson, et al.); and U.S. Pat. No. 6,241,139 (Milliman et al.), the entire contents of each of which are incorporated herein by reference.

Tyco Healthcare Group, LP, the assignee of the present application, has manufactured and marketed endoscopic stapling instruments, such as the Multifire ENDO GIA™. 30 and Multifire ENDO GIA™. 60 instruments, for a number of years. These instruments include a surgical stapling apparatus and a DLU. Typically, the DLU is attached to the apparatus immediately prior to surgery. After use, the DLU can be removed from the apparatus and a new DLU can be fastened to the apparatus to perform additional stapling and/or cutting operations. These instruments have provided significant clinical benefits. Nonetheless, improvements to these instruments are still possible.

It would be desirable to provide a surgical buttress selectively connected to at least one of the tissue contacting surfaces of the cartridge half-section and the anvil half-section of the surgical stapling apparatus.

It would also be desirable to provide a system for removing the surgical buttress from the tissue contacting surface of the cartridge half-section and/or the tissue contacting surface of the anvil half-section during a firing of the surgical stapling apparatus.

Accordingly, it is an object of this disclosure to meet the aforementioned desires.

SUMMARY

In accordance with the present disclosure a surgical stapling apparatus is provided including a housing; a handle supported by the housing; an elongated body extending distally from the housing and having a distal end adapted to releasably engage a loading unit; and a loading unit supportable on a distal end of the housing. The loading unit includes a tool assembly having a cartridge assembly configured and adapted to releasably support a staple cartridge having a plurality of surgical fasteners therein, and an anvil assembly movably secured in relation to the cartridge assembly, wherein the anvil assembly is configured and adapted to support an anvil plate and, wherein each of the anvil plate and the staple cartridge define an elongate longitudinal slot. The loading unit further includes a surgical buttress releasably secured to a tissue contacting surface of at least one of the anvil plate and the staple cartridge, wherein each surgical buttress is secured to the at least one of the anvil assembly and the cartridge assembly by at least one anchor. The loading unit still further includes a drive assembly slidably supported in the tool assembly, the drive assembly including a knife blade slidably disposed within each elongate longitudinal slot, wherein movement of the drive assembly from a proximal position to a distal position results in the knife blade thereof cutting the at least one anchor and freeing each surgical buttress from the respective at least one anvil assembly and cartridge assembly.

The anvil assembly may include a proximal suture securing the surgical buttress thereto and/or a distal anchor securing the surgical buttress thereto. The cartridge assembly may include a proximal anchor securing the surgical buttress thereto and/or a distal anchor securing the surgical buttress thereto. Each anchor of the anvil assembly and the cartridge assembly may extend across the respective longitudinal slot of the anvil plate and the staple cartridge.

The anvil assembly may include a knife blade slidably or rotatably supported therein and defining a knife edge. The knife blade of the anvil assembly may cut at least one of the proximal and distal anchors of the anvil assembly upon actuation thereof. The knife blade of the anvil assembly may have a first position located substantially proximal of the distal anchor of the anvil assembly and a second position located substantially distal of the distal anchor of the anvil assembly, thereby cutting the distal anchor of the anvil assembly. The drive assembly may move the knife blade of the anvil assembly from the first position to the second position upon distal actuation of the drive assembly.

The cartridge assembly may include a knife blade slidably or rotatably supported therein and defining a knife edge, wherein the knife blade of the cartridge assembly cuts at least one of the proximal and distal anchors of the cartridge assembly upon actuation thereof. The knife blade of the cartridge assembly may have a first position located substantially proximal of the distal anchor of the cartridge assembly and a second position located substantially distal of the distal anchor of the cartridge assembly, thereby cutting the distal anchor of the cartridge assembly. The drive assembly may move the knife blade of the cartridge assembly from the first position to the second position upon distal actuation of the drive assembly.

According to another aspect of the present disclosure, a loading unit for use with a surgical stapling apparatus is provided. The loading unit includes a tool assembly having a cartridge assembly configured and adapted to releasably support a staple cartridge having a plurality of surgical fasteners therein, and an anvil assembly movably secured in relation to the cartridge assembly, wherein the anvil assembly is configured and adapted to support an anvil plate and, wherein each of the anvil plate and the staple cartridge define an elongate longitudinal slot. The loading unit also includes a surgical buttress releasably secured to a tissue contacting surface of at least one of the anvil plate and the staple cartridge, wherein each surgical buttress is secured to the at least one of the anvil assembly and the cartridge assembly by at least one anchor. The loading unit further includes a drive assembly slidably supported in the tool assembly, the drive assembly including a knife blade slidably disposed within each elongate longitudinal slot, wherein movement of the drive assembly from a proximal position to a distal position results in the knife blade thereof cutting the at least one anchor and freeing each surgical buttress from the respective at least one anvil assembly and cartridge assembly.

According to yet another aspect of the present disclosure, a loading unit for selective use with a surgical stapling apparatus is provided. The loading unit includes a tool assembly having a cartridge assembly configured and adapted to releasably support a staple cartridge having a plurality of surgical fasteners therein, and an anvil assembly movably secured in relation to the cartridge assembly, wherein the anvil assembly is configured and adapted to support an anvil plate and, wherein each of the anvil plate and the staple cartridge define an elongate longitudinal slot. The loading unit further includes a surgical buttress releasably secured to a tissue contacting surface of each of the anvil plate and the staple cartridge; and anchors securing the surgical buttress to each of the anvil plate and the staple cartridge, wherein an anchor is located near a proximal end and a distal end of each of the anvil assembly and the cartridge assembly. The loading unit also includes a knife blade operatively disposed in the anvil assembly, wherein the knife blade of the anvil assembly has a first position located proximal of a distal anchor of the anvil assembly and a second position located distal of the distal anchor of the anvil assembly, thereby cutting the distal anchor of the anvil assembly. The loading unit still further includes a knife blade operatively disposed in the cartridge assembly, wherein the knife blade of the cartridge assembly has a first position located proximal of a distal anchor of the cartridge assembly and a second position located distal of the distal anchor of the cartridge assembly, thereby cutting the distal anchor of the cartridge assembly. The loading unit also includes a drive assembly slidably supported in the tool assembly, the drive assembly including a knife blade slidably disposed within each elongate longitudinal slot, wherein movement of the drive assembly from a proximal position to a distal position results in the knife blade thereof cutting a proximal anchor of each of the anvil assembly and the cartridge assembly and freeing a proximal end of each surgical buttress from the respective at least one anvil assembly and cartridge assembly, and wherein movement of the drive assembly from the proximal position to the distal position moves the knife blade of the anvil assembly and the knife blade of the cartridge assembly from their respective first positions to their respective second positions, thereby cutting a respective distal anchor of the anvil assembly and the cartridge assembly and freeing a distal end of each surgical buttress from the respective at least one anvil assembly and cartridge assembly.

According to a further aspect of the present disclosure, a surgical stapling apparatus is provided. The surgical stapling apparatus includes a cartridge assembly defining a tissue contacting surface; an anvil assembly defining a tissue contacting surface; and a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor.

An anchor may be placed near at least one of a proximal end and a distal end of each surgical buttress. Each anchor may extend transverse to a longitudinal axis of a respective one of the cartridge assembly and the anvil assembly.

The anchor may be selected from the group consisting of sutures, threads, tethers, straps, bands, lines, wires, cables, tacks, anchors, and fasteners.

At least a proximal anchor may extend across a respective longitudinal knife slot formed in each of the cartridge assembly and the anvil assembly and/or at least a distal anchor may extend across a respective longitudinal knife slot formed in each of the cartridge assembly and the anvil assembly.

The anchor may release a respective surgical buttress upon firing of the surgical stapling apparatus. Each anchor may be severed to release the surgical buttress upon a firing of the surgical stapling apparatus.

The surgical stapling apparatus may include a knife blade configured and dimensioned for slidable reciprocation through a respective longitudinal knife slot formed in each of the cartridge assembly and the anvil assembly, wherein the knife blade severs an anchor upon distal advancement thereof.

The surgical stapling apparatus may further include a drive assembly slidably supported for axial displacement along the cartridge assembly and the anvil assembly, wherein movement of the drive assembly from a proximal position to a distal position results in the separation of the surgical buttress from a respective one of the cartridge assembly and the anvil assembly.

An anchor may be placed near at least one of a proximal end and a distal end of each surgical buttress. The drive assembly may either directly cut each anchor or may cause each anchor to be cut in order to release the surgical buttress from the respective cartridge assembly and anvil assembly.

According to a further embodiment of the present disclosure, a surgical stapling apparatus is provided and includes a cartridge assembly defining a tissue contacting surface and a longitudinally extending elongate slot; an anvil assembly defining a tissue contacting surface and a longitudinally extending elongate slot; and a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor, wherein each buttress defines a notch formed in a proximal edge thereof and substantially aligned with the longitudinally extending elongate slot of a respective cartridge assembly and anvil assembly.

The surgical stapling apparatus may further include a central knife blade slidably disposable in the longitudinal extending elongate slot of the cartridge assembly and the anvil assembly, wherein the central knife blade is received in the notch of each surgical buttress upon an advancement of the central knife blade through the longitudinal extending elongate slot.

Each of the cartridge assembly and the anvil assembly may include a distal pair of constricting slots formed in a respective side edge thereof; and a proximal pair of constricting slots formed in a respective side edge thereof. A suture may extend across respective distal and proximal pairs of constricting slots of the cartridge assembly and the anvil assembly for securing a respective surgical buttress thereto.

Each surgical buttress may include a notch formed in a side edge thereof in registration with each constricting slot.

The surgical stapling apparatus may further include a knife blade supported in a distal end portion of at least one of the cartridge assembly and the anvil assembly. The distal knife blade may be actuatable by the central knife blade upon an actuation of the central knife blade.

The surgical stapling apparatus may still further include a knife blade supported in a distal end portion of at least one of the cartridge assembly and the anvil assembly, wherein the central knife blade is supported on a drive bar, and wherein the distal knife blade is actuatable by at least one of the central knife blade and the drive bar upon an actuation of the drive bar.

According to yet another embodiment of the present disclosure, a surgical stapling apparatus is provided and includes a cartridge assembly defining a tissue contacting surface; an anvil assembly defining a tissue contacting surface, wherein the tissue contacting surface of at least one of the cartridge assembly and the anvil assembly includes a grip enhancing feature formed thereon; and a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor, wherein a position of the surgical buttress relative to a respective cartridge assembly and anvil assembly is better maintained as compared to a cartridge assembly and a anvil assembly devoid of the grip enhancing feature.

The tissue contacting surface of at least one of the cartridge assembly and the anvil assembly may include at least one of a distal grip enhancing feature and a proximal grip enhancing feature.

Each of the cartridge assembly and the anvil assembly may define a longitudinally extending elongate slot, and wherein the tissue contacting surface of at least one of the cartridge assembly and the anvil assembly includes at least one of a distal grip enhancing feature disposed distal of the longitudinally extending elongate slot and a proximal grip enhancing feature disposed on opposed sides of the longitudinally extending elongate slot.

Each grip enhancing feature may be a projection extending from the tissue contacting surface.

According to still a further embodiment of the present disclosure, a surgical stapling apparatus is provided and includes a cartridge assembly defining a tissue contacting surface and a longitudinally extending elongate slot; an anvil assembly defining a tissue contacting surface and a longitudinally extending elongate slot; a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor; a central knife blade slidably disposable in the longitudinal extending elongate slot of the cartridge assembly and the anvil assembly; and a knife blade supported in a distal end portion of at least one of the cartridge assembly and the anvil assembly, wherein the distal knife blade is actuatable by the central knife blade upon an actuation of the central knife blade.

At least one of the distal knife blades may be biased to a proximal position by a biasing member. The biasing member may be at least one of a leaf spring and a coil spring.

The cartridge assembly and the anvil assembly may include a distal suture for securing a distal end of a respective surgical buttress to a tissue contacting surface thereof. Each distal knife blade may sever a respective distal suture upon a firing of the surgical stapling apparatus. Each distal knife blade may have at least a first position disposed proximal of the respective distal suture and at least a second position disposed distal of the respective distal suture. Each distal knife blade may be roatably supported in the respective cartridge assembly and anvil assembly.

At least one distal knife blade may define a concave distal knife edge. At least one distal knife blade may define a double-beveled knife edge. The distal knife edge may be concave.

At least one distal knife blade may define a distally extending tooth projecting therefrom. At least one distal knife blade may define an aperture for pivotal support on a hub, wherein the aperture of the distal knife blade and the hub each define complementary planar surface for maintaining a relative position of the distal knife blade with respect to the at least one anchor prior to a firing of the surgical stapling apparatus.

Additional advantages will become apparent from the description which follows, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be further described with reference to the accompanying drawings, wherein like reference numerals refer to like parts in the several views, and wherein:

FIG. 1 is a perspective view of a surgical stapling apparatus according to an embodiment of the present disclosure;

FIG. 2 is a top, exploded perspective view of a distal end of a DLU of the surgical stapling apparatus ofFIG. 1;

FIG. 3 is a top, perspective view of the DLU ofFIG. 2, shown in an assembled condition;

FIG. 4 is a top, perspective view of a distal end of the DLU ofFIG. 2;

FIG. 5 is a further top, perspective view of the distal end of the DLU ofFIGS. 2 and 4, having a top, front cover removed therefrom;

FIG. 6 is a top, perspective view of a proximal end of the DLU ofFIGS. 2-5;

FIG. 7 is a side, elevational view of the distal end of the DLU ofFIGS. 2-6;

FIG. 8 is a top, plan view of the distal end of the DLU ofFIGS. 2-7;

FIG. 9 is a bottom, perspective view of a distal end of an anvil half-section of the DLU ofFIGS. 2-8, illustrating a knife assembly associated therewith;

FIG. 10 is a bottom, perspective view of a proximal end of the anvil half-section ofFIG. 9, illustrating the knife assembly associated therewith;

FIG. 11 is a top, perspective view of a distal end of a cartridge half-section of the DLU ofFIG. 2;

FIG. 12 is a side, elevational view of the distal end of the cartridge half-section of the DLU ofFIGS. 2 and 11

FIG. 13 is a bottom, perspective view of the distal end of the cartridge half-section of the DLU ofFIGS. 2,11 and12;

FIG. 14 is a further bottom, perspective view of the distal end of the cartridge half-section of the DLU of FIGS.2 and11-13;

FIG. 15 is an enlarged, perspective view of the indicated area of detail ofFIG. 13;

FIG. 16 is a bottom, enlarged, perspective view of the distal end of the cartridge half-section of the DLU of FIGS.2 and11-15;

FIG. 17 is a bottom, plan view of the distal end of the cartridge half-section of the DLU of FIGS.2 and11-16;

FIG. 18 is a longitudinal, cross-sectional view of the distal end of the cartridge half-section of the DLU of FIGS.2 and11-17;

FIG. 19 is a bottom, perspective view of the distal end of the cartridge half-section of the DLU of FIGS.2 and11-18;

FIG. 20 is an exploded, perspective view of a distal end of a DLU of the surgical stapling apparatus ofFIG. 1, according to another embodiment of the present disclosure;

FIG. 21 is perspective view of the distal end of the DLU ofFIG. 20;

FIG. 22 is a top, perspective view of a distal end of an anvil half-section of the DLU ofFIGS. 20 and 21;

FIG. 23 is a bottom, perspective view of the distal end of the anvil half-section ofFIG. 22, having an anvil plate removed therefrom;

FIG. 24 is a top, perspective view of a proximal end of the anvil half-section of the DLU ofFIGS. 20 and 21;

FIG. 25 is a bottom, perspective view of the proximal end of the anvil half-section ofFIG. 24;

FIG. 26 is a top, perspective view of a cartridge half-section of the DLU ofFIGS. 20 and 21;

FIG. 27 is a top, perspective view of a distal end of the cartridge half-section ofFIG. 26;

FIG. 28 is a top, perspective view of the distal end of the cartridge half-section ofFIG. 27, having a blade stop insert removed therefrom;

FIG. 29 is a side elevational view of the distal end of the cartridge half-section ofFIG. 28;

FIG. 30 is a top, perspective view of the blade stop insert of the cartridge half-section ofFIGS. 26 and 27;

FIG. 31 is a bottom, perspective view of the blade stop insert of the cartridge half-section ofFIGS. 26 and 27;

FIG. 32 is a perspective view of the distal end of the cartridge half-section ofFIGS. 26 and 27, having a distal nose cap removed therefrom;

FIG. 33 is a perspective view of a distal end of a cartridge assembly, according to another embodiment of the present disclosure, of a DLU of a surgical stapling apparatus;

FIG. 34 is a perspective view of a distal end of an anvil assembly, according to another embodiment of the present disclosure, of a DLU of a surgical stapling apparatus;

FIG. 35 is a top, plan view of the distal end of the anvil assembly ofFIG. 34, illustrating a knife blade thereof in a first position;

FIG. 36 is a top, plan view of the distal end of the anvil assembly ofFIGS. 34 and 35, illustrating the knife blade thereof in a second position;

FIG. 37 is a perspective view of a distal end of a cartridge assembly, according to another embodiment of the present disclosure, of a DLU of a surgical stapling apparatus;

FIG. 38 is a top, plan view of the distal end of the cartridge assembly ofFIG. 37, illustrating a knife blade thereof in a first position;

FIG. 39 is a top, plan view of the distal end of the cartridge assembly ofFIGS. 37 and 38, illustrating the knife blade thereof in a second position;

FIG. 40 is a perspective view of a distal end of an anvil assembly, according to yet another embodiment of the present disclosure, of a DLU of a surgical stapling apparatus;

FIG. 41 is a top, plan view of the distal end of the anvil assembly ofFIG. 40, illustrating a knife blade thereof in a first position;

FIG. 42 is a top, plan view of the distal end of the anvil assembly ofFIGS. 40 and 41, illustrating the knife blade thereof in a second position;

FIG. 43 is a perspective view of a distal end of a cartridge assembly, according to yet another embodiment of the present disclosure, of a DLU of a surgical stapling apparatus;

FIG. 44 is a top, plan view of the distal end of the cartridge assembly ofFIG. 43, illustrating a knife blade thereof in a first position;

FIG. 45 is a top, plan view of the distal end of the cartridge assembly ofFIGS. 43 and 44, illustrating the knife blade thereof in a second position;

FIG. 46 is a schematic, perspective view of a distal end of an anvil assembly, according to still another embodiment of the present disclosure, of a DLU of a surgical stapling apparatus;

FIG. 47 is an exploded, perspective view of a DLU of the surgical stapling apparatus ofFIG. 1, according to another embodiment of the present disclosure;

FIG. 48 is a side elevational view of the DLU ofFIG. 47;

FIG. 49 is an exploded perspective view of the DLU ofFIGS. 47 and 48;

FIG. 50 is an enlarged perspective view of an actuation sled of the DLU ofFIGS. 47-49;

FIG. 51 is an enlarged perspective view of the DLU ofFIGS. 47-49, shown in a closed condition;

FIG. 52 is an enlarged view of the indicated area of detail ofFIG. 47;

FIG. 53 is a longitudinal cross-sectional elevation view of the DLU, as taken through53-53 ofFIG. 47;

FIG. 54 is an enlarged view of the indicated area of detail ofFIG. 53;

FIG. 55 is an enlarged view of the indicated area of detail ofFIG. 53;

FIG. 56 is a perspective view of a cartridge assembly of the DLU ofFIGS. 47-49;

FIG. 57 is an enlarged perspective view of a distal end of the cartridge assembly ofFIG. 56;

FIG. 58 is an enlarged view of the indicated area of detail ofFIG. 56;

FIG. 59 is an enlarged view of the indicated area of detail ofFIG. 58;

FIG. 60 is a perspective view, with parts separated, of the distal end of the cartridge assembly ofFIG. 56;

FIG. 61 is a bottom, perspective view of a knife blade assembly of the cartridge assembly ofFIG. 56;

FIG. 62 is a top, perspective view of a knife blade assembly of the cartridge assembly ofFIG. 56;

FIG. 63 is a bottom, perspective view of a proximal end of an anvil assembly of the DLU ofFIGS. 47-49;

FIG. 64 is a perspective view, with parts separated, of the anvil assembly ofFIG. 63;

FIG. 65 is a bottom, perspective view of the anvil assembly ofFIGS. 63 and 64;

FIG. 66 is a bottom, perspective view of the anvil assembly ofFIG. 65, with a buttress removed therefrom;

FIG. 67 is a bottom, perspective view of the anvil assembly ofFIG. 65, with a buttress and an anvil plate removed therefrom;

FIG. 68 is a longitudinal cross-sectional elevation view of the DLU, as taken through53-53 ofFIG. 47, illustrating an initial actuation of a drive assembly thereof;

FIG. 69 is an enlarged view of the indicated area of detail ofFIG. 68;

FIG. 70 is a longitudinal cross-sectional elevation view of the DLU, as taken through53-53 ofFIG. 47, illustrating a final actuation of the drive assembly thereof;

FIG. 71 is an enlarged view of the indicated area of detail ofFIG. 70;

FIG. 72 is an enlarged distal perspective view of the DLU ofFIGS. 70 and 71, following an actuation thereof;

FIG. 73 is a schematic, perspective illustration of the actuation sled engaging a knife blade assembly;

FIG. 74 is a top, plan view of the actuation sled engaging a knife blade assembly;

FIG. 75 is an enlarged perspective view of a distal end of the cartridge assembly following a complete actuation of the drive assembly;

FIG. 76 is a perspective view of a cartridge assembly of a DLU according to another embodiment of the present disclosure, including a surgical cartridge buttress according to another embodiment of the present disclosure;

FIG. 77 is an enlarged view of the indicated area of detail ofFIG. 76;

FIG. 78 is a perspective view of the cartridge assembly ofFIGS. 76-77, with the surgical cartridge buttress removed therefrom;

FIG. 79 is a cross-section view taken through79-79 ofFIG. 78;

FIG. 80 is a cross-section view taken through80-80 ofFIG. 78;

FIG. 81 is a perspective view of an anvil assembly of a DLU according to another embodiment of the present disclosure, including a surgical anvil buttress according to another embodiment of the present disclosure;

FIG. 82 is a plan view of a distal end of the anvil assembly ofFIG. 81, with an anvil plate removed therefrom, illustrating a knife blade housing supporting an anvil knife blade thereon;

FIG. 83 is a perspective view, with parts separated, of the knife blade housing and anvil knife blade ofFIG. 82;

FIG. 84 is a perspective view of the knife blade housing and anvil knife blade ofFIGS. 82 and 83, shown in an assembled condition;

FIG. 84A is a cross-sectional view as taken through84A-84A ofFIG. 84;

FIG. 85 is a bottom perspective view of the cartridge assembly ofFIGS. 76-78;

FIG. 86 is a perspective view of an anvil blade housing according to another embodiment of the present disclosure including an anvil knife blade rotatable connected thereto and supported thereon;

FIG. 87 is a perspective view of an anvil blade housing according to yet another embodiment of the present disclosure including an anvil knife blade rotatable connected thereto and supported thereon;

FIG. 88 is a plan view of the anvil blade housing and anvil blade ofFIG. 87, shown in an unactuated condition;

FIG. 89 is a plan view of the anvil blade housing and anvil blade ofFIGS. 87 and 88, shown in an actuated condition; and

FIG. 90 is a perspective view of an anvil blade according to a further embodiment of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical stapling apparatus and DLU will now be described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views.

In the drawings and in the description that follows, the term “proximal”, as is traditional, will refer to the end of the stapling apparatus which is closest to the operator, while the term “distal” will refer to the end of the apparatus which is furthest from the operator.

FIG. 1 shows a surgical apparatus, e.g., surgical stapling apparatus, generally referred to as10. In the interest of brevity, this disclosure will focus primarily on systems, methods and structures for loading, engaging, coupling or connecting a disposable loading unit (“DLU”)16 tosurgical stapling apparatus10. A detailed discussion of the remaining components and method of use ofsurgical stapling apparatus10 is disclosed in U.S. Pat. No. 6,241,139.

Surgical stapling apparatus10 is an endoscopic apparatus and includes ahandle assembly12 and anelongated body14 extending fromhandle assembly12. ADLU16 is releasably secured to the distal end ofelongated body14. While this disclosure relates to the use of a DLU withsurgical stapling apparatus10, it is understood and within the scope of the present disclosure that a single use loading unit (SULU) or other end effector and/or tool assembly can equally be used in cooperation withsurgical stapling apparatus10.

DLU16 includes atool assembly17 having acartridge assembly18 housing a plurality of surgical fasteners or staples84 (seeFIG. 2) and ananvil assembly20 movably secured in relation tocartridge assembly18. As shown herein,DLU16 is configured to apply six (6) linear rows of staples, in DLUs measuring from about 30 mm to about 60 mm in length. DLUs for applying any number of rows of staples, having staple pockets arranged in various patterns and/or DLUs and end effectors having any other lengths, e.g., 45 mm, are also envisioned. Handleassembly12 includes astationary handle member22, amovable handle member24, and abarrel portion26.

Arotatable member28 is mounted on the forward end ofbarrel portion26 to facilitate rotation ofelongated body14 and attachedDLU16 with respect to handleassembly12. Anarticulation lever30 is also mounted on the forward end ofbarrel portion26 adjacentrotatable member28 to facilitate articulation oftool assembly17. Preferably, a pair ofknobs32 are movably positioned alongbarrel portion26.Knobs32 are advanced distally to approximate or close cartridge and/oranvil assembly18,20, and retracted proximally to unapproximate or open cartridge and/oranvil assembly18,20.

DLU16 is desirably selectively removably couplable toelongated body14.DLU16 includes ahousing portion36 having a proximal end adapted to releasably engage the distal end ofelongated body14. A mounting assembly38 is pivotally secured at “P” to the distal end ofhousing portion36, and is configured to receive the proximal end oftool assembly17 such that pivotal movement oftool assembly17 about an axis at “P”, perpendicular to the longitudinal axis ofhousing portion36, effects articulation oftool assembly17.

With general reference toFIGS. 2-8,DLU16 includes a mounting assembly40. Mounting assembly40 includes an upper and a lower mountingportion40a,40b, respectively. A centrally located pivot member42 extends from each of upper and lower mountingportions40a,40b.

Anaxial drive assembly50 is operatively associated with and slidably disposed between cartridge and/oranvil assembly18,20. With reference toFIG. 2,axial drive assembly50 includes anelongated drive beam52 having adistal end54 and aproximal end56.Drive beam52 may be constructed from a single sheet of material or, preferably, multiple stacked sheets.

Proximal end56 ofdrive beam52 ofdrive assembly50 includes a pair of resilient engagement fingers which are dimensioned and configured to mountingly engage a drive member, e.g., a drive rod or control rod (not shown) when the proximal end ofDLU16 is engaged withelongated body14 ofsurgical stapling apparatus10. The control rod functions to impart axial movement ofdrive assembly50 fromhandle assembly12.

Distal end54 ofdrive beam52 ofdrive assembly50 is configured and adapted to support an I-Beam60. I-beam60 includes acentral wall portion62 and an upper andlower rail portion64a,64b, respectively. A distal edge ofcentral wall portion62 defines a knife blade or the like66.

As seen inFIGS. 2-10,anvil assembly20 includes ananvil plate70 having a plurality of staple deforming pockets/cavities70a(seeFIGS. 9 and 10) and acover plate72 secured to a top surface ofanvil plate70, wherein a cavity (not shown) is defined therebetween. The cavity defined betweenanvil plate70 andcover plate72 is dimensioned to slidably receiveupper rail portion64aof I-beam60 therein. Alongitudinal slot70bextends throughanvil plate70 to facilitate passage ofcentral wall portion62 of I-beam60 therethrough.

In operation, an upper surface ofanvil plate70 defines acamming surface70cagainst whichupper rail portion64aof I-beam60 engages to cam, urge and clampanvil assembly20 against the tissue asdrive assembly50 advances I-beam60 throughlongitudinal slot70b.

With continued reference toFIGS. 2-10,anvil plate70 defines a proximal pair ofrecesses70dformed near a proximal end ofanvil plate70 and disposed, one each, on opposed sides oflongitudinal slot70b.Anvil plate70 defines a distal pair ofrecesses70eformed near a distal end ofanvil plate70 and disposed, one each, on opposed sides oflongitudinal slot70b. In one embodiment, at least one of the recesses of each of the proximal pair ofrecesses70dand the distal pair ofrecesses70eis non-circular, preferably, constricting, so as to frictionally engage and/or pinch an anchor “S”.

As used herein the term anchor is understood to include and is not limited to suture, thread, tether, strap, band, line, wire, cable, fastener, tack, anchor or any other material suitable for the intended purpose disclosed herein.

Anvil assembly20 further includes aknife blade74 defining a distally orientedknife edge74aand being operatively interposed within the cavity defined betweenanvil plate70 andcover plate72.Knife blade74 has an initial or first condition positioned proximal of the distal pair ofrecesses70eand a final or second condition positioned distal of the distal pair ofrecesses70e.Knife blade74 includes an engagingelement74b, e.g., a recess, formed in a surface thereof for selectively engaging a complementary engaging element, e.g., nub, (not shown) projecting from a surface ofcover plate72, or adistal cap76 ofanvil assembly20. The engaging elements inter-engage with one another to maintain or holdknife blade74 stationary and in the initial or first condition.

In an embodimentdistal cap76 includes a pair ofopposed recesses76aformed in opposed side edges thereof which align with the distal pair ofrecesses70eformed inanvil plate70 whencover plate72 is assembled withanvil plate70. Additionally,cover plate72 defines a pair ofopposed recesses72aformed therein which align with the proximal pair ofrecesses70dformed inanvil plate70 whencover plate72 is assembled withanvil plate70.

Anvil assembly20 further includes a surgical buttress “B”, pledget or the like operatively secured to a lower surface ofanvil plate70, by anchor “S”, to overlie at least some of anvil pockets70aand/or at least a portion of a length oflongitudinal slot70b. In particular, an anchor “S” is threaded through a distal portion of the anvil buttress “B” and each of the distal pair ofrecesses70e, and an anchor “S” is threaded through a proximal portion of anvil buttress “B” and each of the proximal pair ofrecesses70d.

In one particular embodiment, a first end of a anchor “S” includes a knot, stop or the like (not shown) sized so as to not pass through one recess of the proximal pair ofrecesses70dwhile a second end of anchor “S” passes through, and transversely across, anvil buttress “B”, at least once, and back through the other recess of the proximal pair ofrecesses70d. For example, the second end of anchor “S” may be pinched or cinched in the other recess of the proximal pair ofrecesses70dso as to anchor the second end of the anchor “S” and secure the anvil buttress “B” against the lower surface ofanvil plate70. Similarly, an anchor “S” is used to extend transversely across anvil buttress “B” and into engagement with the distal pair ofrecesses70e.

In operation, as will be discussed in greater detail below, with anvil buttress “B” secured against the lower surface ofanvil plate70, during firing ofsurgical stapling apparatus10, asdrive assembly50 is advanced (i.e., moved from a proximal-most position to a distal-most position),knife blade66 slices through a central section of the proximal anchor “S”, thereby freeing the proximal end of the anvil buttress “B” fromanvil assembly20. Asdrive assembly50 approaches the distal end ofanvil plate70,upper rail64aof I-beam60 abuts against and urgesknife blade74 distally. Asknife blade74 is moved distally, from the initial or first condition positioned proximal of the distal pair ofrecesses70eto the final or second condition positioned distal of the distal pair ofrecesses70e,knife edge74athereof slices or cuts through distal anchor “S”, thereby freeing the distal end of the anvil buttress “B” fromanvil assembly20.Knife blade74 cuts through the distal anchor “S” extending through both recesses of the distal pair ofrecesses70e.

As seen inFIGS. 2-8 and11-19,cartridge assembly18 includes acarrier80 defining anelongated support channel80a.Elongated support channel80aofcarrier80 is dimensioned and configured to selectively receive astaple cartridge82 therein. Corresponding tabs and slots formed alongstaple cartridge82 andcarrier80 function to retainstaple cartridge82 withincarrier80. A pair of support struts formed on and extending fromstaple cartridge82 are positioned to rest on side walls ofcarrier80 to further stabilizestaple cartridge82 withinsupport channel80aofcarrier80.Staple cartridge82 includesretention slots82aformed therein for receiving a plurality offasteners84 and pushers86. A plurality of spaced apartlongitudinal slots82bextend throughstaple cartridge82 to accommodateupstanding cam wedges90aofactuation sled90.Actuation sled90 includes a central upstanding wedge orwall90b.Central wall90bdefines a distal notch orshoulder90cformed therein.

A centrallongitudinal slot82cis formed in and extends along the length ofstaple cartridge82 to facilitate passage ofcentral wall portion62 of I-beam60 therethrough. During operation ofsurgical stapler10,actuation sled90 translates throughlongitudinal slots82bofstaple cartridge82 to advancecam wedges90ainto sequential contact withpushers92, to causepushers92 to translate vertically withinretention slots82aand urge fasteners84 (e.g., staples) fromslots82ainto thestaple forming cavities70aofanvil plate70 ofanvil assembly20.

With continued reference to FIGS.2 and11-19,staple cartridge82 defines a proximal pair ofrecesses82eformed near a proximal end thereof and disposed, one each, on opposed sides oflongitudinal slot82c.Staple cartridge82 further defines a distal pair ofrecesses82fformed near a distal end thereof and disposed, one each, on opposed sides oflongitudinal slot82c. In one embodiment, at least one of the recesses of each of the proximal pair ofrecesses82eand the distal pair ofrecesses82fis non-circular, preferably, constricting, so as to frictionally engage and/or pinch an anchor “S”.

Cartridge assembly18 further includes aknife blade94 defining a distally orientedknife edge94a(seeFIGS. 12-17 and19) and being operatively disposed within acavity82d(seeFIGS. 16,17 and19) defined near a distal end ofstaple cartridge82.Knife blade94 may include a right side and a leftside knife edge94a.Knife blade94 has an initial or first condition positioned proximal of a distal pair ofrecesses82eformed instaple cartridge82 and a final or second condition positioned distal of the distal pair ofrecesses82e.

Knife blade94 may include an engaging element (not shown) formed in a surface thereof for selectively engaging a complementary engaging element (not shown) projecting from a surface ofstaple cartridge82 ofcartridge assembly18. The engaging elements inter-engage with one another to maintain or holdknife blade94 stationary and in the initial or first condition.

Cartridge assembly18 further includes a surgical buttress “B”, pledget or the like operatively secured to an upper surface ofstaple cartridge82, by anchors “S”, to overlie at least some ofstaple pockets82aand/or at least a portion of a length oflongitudinal slot82c. In particular, an anchor “S” is threaded through a distal portion of the cartridge buttress “B” and each of the distal pair ofrecesses82f, and an anchor “S” is threaded through a proximal portion of cartridge buttress “B” and each of the proximal pair ofrecesses82e.

In one particular embodiment, a first end of each anchor “S” includes a knot, stop or the like (not shown) sized so as to not pass through one recess of the proximal pair ofrecesses82eand a second end of each anchor “S” passes through, and transversely across, cartridge buttress “B”, at least once, and back through the other recess of the proximal pair ofrecesses82e. For example, the second end of each anchor “S” may be pinched or cinched in the other recess of the proximal pair ofrecesses82eso as to anchor the second end of the anchor “S” and secure the cartridge buttress “B” against the tissue contacting surface ofstaple cartridge82. Similarly, an anchor “S” is used to extend transversely across cartridge buttress “B” and into engagement with the distal pair ofrecesses82f.

In operation, as will be discussed in greater detail below, with cartridge buttress “B” secured against the tissue contacting surface ofstaple cartridge82, during firing ofsurgical stapling apparatus10, asdrive assembly50 is advanced (i.e., moved from a proximal-most position to a distal-most position),knife blade66 slices through a central section of the proximal anchor “S”, thereby freeing the proximal end of the cartridge buttress “B” fromcartridge assembly18. As seen inFIG. 18, asdrive assembly50 approaches the distal end ofstaple cartridge82,shoulder90cof central upstanding wedge orwall90bofactuation sled90 abuts against and urgesknife blade94 distally. Asknife blade94 is moved distally, from the initial or first condition positioned proximal of the distal pair ofrecesses82fto the final or second condition positioned distal of the distal pair ofrecesses82f, knife edges94athereof slice or cut through distal anchor “S”, thereby freeing the distal end of the cartridge buttress “B” fromcartridge assembly18.Knife blade94 cuts through the distal anchor “S” extending through both recesses of the distal pair ofrecesses82f.

Asdrive assembly50 is advanced from a proximal-most position to a distal-most position,knife blade66 thereof slices or cuts longitudinally through both anvil buttress “B” and cartridge buttress “B”, thereby dividing the buttresses “B” substantially in half. Additionally, asdrive assembly50 is advanced from a proximal-most position to a distal-most position,upstanding cam wedges90aofactuation sled90 actuatespushers92, to causepushers92 to translate vertically withinretention slots82aandurge fasteners84 fromslots82a. As fasteners84 (e.g., staples) are urged fromslots82aofstaple cartridge82, legs offasteners84 penetrate and pass through both anvil buttress “B” and cartridge buttress “B”, through any tissue (not shown) interposed between anvil buttress “B” and cartridge buttress “B”, and are formed against or within staple formingcavities70aofanvil plate70 ofanvil assembly20.

According to the present disclosure, anvil buttress “B” and/or cartridge buttress “B” is pre-loaded (i.e., from the manufacturer) ontoanvil assembly20 orcartridge assembly18, respectively, ofDLU17. Additional or replacement buttresses “B” foranvil assembly20 and/orcartridge assembly18 may be secured to eitheranvil assembly20 orcartridge assembly18 as needed or desired.

In operation, withDLU17 coupled to a distal end ofelongated body14 ofsurgical stapling apparatus10, and with anvil buttress “B” and cartridge buttress “B” pre-loaded ontoanvil assembly20 andcartridge assembly18, respectively,surgical stapling apparatus10 is used in accordance with methods known by those skilled in the art. Onceanvil assembly20 andcartridge assembly18 are clamped onto tissue,surgical stapling apparatus10 is fired. In firingsurgical stapling apparatus10,drive assembly50 is advanced from a proximal-most position to a distal-most position. In so doing,knife blade66 ofdrive assembly50 substantially simultaneously slices or cuts through a central section of the proximal anchor “S” ofanvil assembly20 andcartridge assembly18, thereby respectively freeing the proximal end of anvil buttress “B” and cartridge buttress “B” therefrom.

Asdrive assembly50 approaches the distal-most position,upper rail64aof I-beam60 abuts against and urgesknife blade74 distally while, substantially simultaneously or concomitantly therewith,shoulder90cof central upstanding wedge orwall90bofactuation sled90 abuts against and urgesknife blade94 distally. Asknife blade74 is moved distally, from the initial position to the final position,knife edge74athereof slices or cuts through distal anchor “S” ofanvil assembly20, thereby freeing the distal end of the anvil buttress “B” fromanvil assembly20. Asknife blade94 is moved distally, from the initial position to the final position, knife edges94athereof slice or cut through distal anchor “S” ofcartridge assembly18, thereby freeing the distal end of the cartridge buttress “B” fromcartridge assembly18.

Also,knife blade66 ofdrive assembly50 substantially simultaneously slices or cuts longitudinally through both anvil buttress “B” and cartridge buttress “B”, thereby dividing the buttresses “B” substantially in half.

Turning now toFIGS. 20-32, a DLU according to another embodiment of the present disclosure, forsurgical stapling apparatus10, is generally designated as116. DLU116 is substantially similar toDLU16 and will only be discussed in detail herein to the extent necessary to identify differences in construction and operation.

As seen inFIGS. 20-25,anvil assembly20 of DLU116 defines a proximal pair ofrecesses70dformed near a proximal end ofanvil plate70 and disposed, one each, on opposed sides oflongitudinal slot70b; and a distal pair ofrecesses70eformed near a distal end ofanvil plate70 and disposed, one each, on opposed sides oflongitudinal slot70b. As best seen inFIGS. 22,24 and25, at least one recess of each of the proximal pair ofrecesses70dand the distal pair ofrecesses70eis in the form of a notch having a constricting configuration so as to frictionally cinch, receive and secure a suture, thread or the like therein.

As seen inFIG. 23,knife blade74 includes anorientation member74c, in the form of a fin or tab, extending from an underside thereof and configured and adapted for slidable engagement inlongitudinal slot70bofanvil plate70.Orientation member74cfunctions to help maintain a proper or desired orientation ofknife blade74. For example,orientation member74cofknife blade74 may aid in maintainingknife edge74aat a substantially orthogonal orientation with respect tolongitudinal slot70b.

As seen inFIGS. 20,21 and26-32,staple cartridge82 ofcartridge assembly18 of DLU116 defines a proximal pair ofrecesses82eformed near a proximal end thereof and disposed, one each, on opposed sides oflongitudinal slot82c; and a distal pair ofrecesses82fformed near a distal end thereof and disposed, one each, on opposed sides oflongitudinal slot82c.

In an embodiment, as seen inFIGS. 20 and 26, it is contemplated thatstaple cartridge82 may include at least one post extending from an upper surface thereof, and the surgical buttress “B” that is to overliestaple cartridge82 may include a respective complementary aperture formed therein. In this manner, when surgical buttress “B” is placed onstaple cartridge82, the aperture(s) thereof and the post(s) ofstaple cartridge82 cooperate with one another to substantially orient and align the surgical buttress “B” overstaple cartridge82.

Staple cartridge82 defines adistal recess82gformed therein for selectively receiving aknife blade insert83 therein. As seen inFIGS. 20,21 and26-32,distal recess82gofstaple cartridge82 defines a plane that is substantially parallel to a tissue contacting surface thereof and includes an extension that is substantially aligned withlongitudinal slot82c.

As seen inFIG. 31,knife blade insert83 includes aprojection83a, in the form of a nub or the like, for snap-fit engaging acomplementary receiving structure74a(seeFIG. 20) formed inknife blade74 of cartridge assembly18 (seeFIG. 2). While aknife blade insert83 having aprojection83ais shown, it is envisioned thatknife blade insert83 may include a recess or depression formed therein that is configured and adapted for snap-fit engagement with a complementary projection extending fromknife blade74.

As seen inFIG. 32, knife blade insert83 functions to maintainknife blade74 in the first condition, i.e., located proximal of the distal pair ofrecesses82fofstaple cartridge82, until actuated bydrive assembly50.

Turning now toFIG. 33, a distal end of acartridge assembly18, in accordance with another embodiment of the present disclosure, is generally designated as118. Cartridge assembly118 is substantially similar tocartridge assembly18 and will only be discussed in detail herein to the extent necessary to identify differences in construction and operation.

As best seen inFIGS. 22,24 and25, at least one recess of each of the proximal pair ofrecesses70dand the distal pair ofrecesses70eis in the form of a notch having a constricting configuration so as to frictionally cinch, receive and secure a suture, thread or the like therein. As seen inFIG. 33,cartridge assembly18 includes aknife blade194 operatively secured in a distal end ofcarrier80 orstaple cartridge82. Ifknife blade194 is supported instaple cartridge82,knife blade194 is replaced whenstaple cartridge82 is replaced.

Knife blade194 includes anarm194ahaving a distal end secured near a distal end ofcarrier80 orstaple cartridge82, and a proximal end extending substantially towardhandle assembly12 ofsurgical stapling apparatus10.Knife blade194 includes aknife edge194bextending from proximal end ofarm194ain a direction substantially parallel withlongitudinal slot82cofstaple cartridge82.Knife edge194bofknife blade194 is substantially aligned between the distal pair ofrecesses82fofstaple cartridge82, such thatknife edge194bis in juxtaposed alignment with an anchor “S” extending between the distal pair ofrecesses82fofstaple cartridge82.Arm194aofknife blade194 has an initial condition whereinknife edge194bis spaced away from anchor “S” extending between the distal pair ofrecesses82fofstaple cartridge82.

In operation, asdrive assembly50 is advanced distally, actuation sled90 (e.g., centralupstanding wedge90b) engages against the proximal end ofarm194aofknife blade194 thereby biasing and camming the proximal end ofarm194aofknife blade194 towards anchor “S” extending between the distal pair ofrecesses82fofstaple cartridge82 such thatknife edge194bthereof severs or otherwise cuts through anchor “S” to free surgical buttress “B” fromstaple cartridge82.

Knife edge194bis retracted intostaple cartridge82 as a result of the spring force created byarm194ain returning to the un-biased or initial condition. Alternatively, as seen inFIG. 33, a biasingmember195, in the form of a compression spring or the like, may be interposed between or operatively associated withcarrier80 andactuation sled90. In this manner, upon a completion of a firing stroke,actuation sled90compresses biasing member195, and upon a removal of the force required to complete the firing stroke, biasingmember195 extends and thus urgesactuation sled90 in a proximal direction thereby allowingknife edge194bto retract intostaple cartridge82.

Exemplary surgical buttresses “B” for use with the surgical stapling devices disclosed herein are shown and described in commonly assigned U.S. Pat. Nos. 5,542,594; 5,908,427; 5,964,774; and 6,045,560, and commonly assigned U.S. Application Serial Nos. 2006/0085034, filed on Apr. 20, 2006; and 2006/0135992, filed on Jun. 22, 2006, the entire contents of each of which is incorporated herein by reference.

As seen throughout the figures, and in particularFIGS. 2,9-11,13,14,20 and26, each surgical buttress “B” may be provided with a pair of proximal and/or a pair of distal, spaced apart holes formed therein, wherein the proximal and/or distal holes of the surgical buttress “B” align with and/or are in juxtaposed relation to respective proximal and/or distal recesses of the anvil plate and/or staple cartridge. The holes of the surgical buttress “B” allow for more efficient and easier attachment of surgical buttress “B” to the anvil plate and/or staple cartridge by anchors “S”.

Turning now toFIGS. 34-36, an anvil assembly according to another embodiment of the present disclosure, for use in a DLU of a surgical stapling apparatus, is generally designated as220.Anvil assembly220 is substantially similar toanvil assemblies20 and thus will only be discussed herein to the extent necessary to identify differences in construction and operation thereof.

As seen inFIGS. 34-36,anvil assembly220 includes aknife blade274 pivotally secured thereto, in particular, near a distal end thereof.Knife blade274 is positioned so as to rotate about a pivot point to sever anchor “S” as drive assembly50 (seeFIG. 2) is advanced to a distal-most position inanvil assembly220.

In particular, with continued reference toFIGS. 34-36,anvil assembly220 includes apivot point276bformed indistal cap276, incover plate272 and/or inanvil plate270 for pivotally engaging or supportingknife blade274.Knife blade274 includes alobe274adefining apivot window274bconfigured and dimensioned to pivotally engagepivot point276b.Pivot point276bandpivot window274bdefine a pivot axis “Y” that is spaced a distance from a longitudinal axis “X” oflongitudinal slot270bofanvil plate270.

Knife blade274 defines acamming edge274cextending acrosslongitudinal slot270bofanvil plate270, and aknife edge274dextending transverse tocamming edge274c.Knife blade274 is configured and dimensioned such that a portion ofcamming edge274cand/or a portion ofknife edge274dextend across anchor “S”.

As seen inFIGS. 34 and 35,knife blade274 has a first position in whichknife edge274ddoes not extend acrossrecesses270eand is out of engagement with anchor “S”. In particular, when in the first position,knife edge274dofknife blade274 includes a portion extending proximally ofrecesses270eand a portion extending distally ofrecesses270e. Additionally, when in the first position,knife edge274dofknife blade274 is disposed betweenrecesses270e. Also, when in the first position,camming edge274cofknife blade274 includes at least a portion extending proximally ofrecesses270e.

As seen inFIG. 36,knife blade274 has a second position in whichknife edge274dextends across arecess270eand is in engagement with anchor “S”. In particular, when in the second position,knife edge274dofknife blade274 includes a portion extending or disposed beyondrecess270e.

In operation, during firing ofsurgical stapling apparatus10, as drive assembly50 (seeFIG. 2) is advanced (i.e., moved from a proximal-most position to a distal-most position),drive assembly50 causesknife blade274 to slice through anchor “S”, thereby freeing the distal end of the anvil buttress (seeFIG. 2). In particular, withknife blade274 in the first position, as seen inFIG. 35, asdrive assembly50 is advanced distally, drive assembly50 contacts or engagescamming edge274cofknife blade274, as indicated by arrow “A”. Asdrive assembly50 is further advanced distally, driveassembly50 creates a moment aroundpivot point276bcausingknife blade274 to rotate thereabout, as indicated by arrow “B”. In so doing, as seen inFIG. 36,knife edge274dofknife blade274 is advanced or rotated through anchor “S” thus severing anchor “S” and freeing the distal end of the anvil buttress (seeFIG. 2).

Turning now toFIGS. 37-39, a cartridge assembly according to another embodiment of the present disclosure, for use in a DLU of a surgical stapling apparatus, is generally designated as218.Cartridge assembly218 is substantially similar tocartridge assemblies18 and thus will only be discussed herein to the extent necessary to identify differences in construction and operation thereof.

As seen inFIGS. 37-39,cartridge assembly218 includes aknife blade294 pivotally secured thereto, in particular, near a distal end thereof.Knife blade294 is positioned so as to rotate about a pivot point to sever anchor “S” as drive assembly50 (seeFIG. 2) is advanced to a distal-most position incartridge assembly218.

In particular, with continued reference toFIGS. 37-39,cartridge assembly218 includes apivot point283aformed inknife blade insert283 and/orstaple cartridge282 for pivotally engaging or supportingknife blade294.Knife blade294 includes alobe294adefining apivot window294bconfigured and dimensioned to pivotally engagepivot point283a.Pivot point283aandpivot window294bdefine a pivot axis “Y” that is spaced a distance from a longitudinal axis “X” oflongitudinal slot282cofstaple cartridge282.

Knife blade294 defines a back orcamming edge294cextending acrosslongitudinal slot282cofstaple cartridge282, and aknife edge294dextending parallel tocamming edge294c.Knife blade294 is configured and dimensioned such thatcamming edge294candknife edge294dare located proximal of anchor “S”.

As seen inFIGS. 37 and 38,knife blade294 has a first position in whichknife edge294ddoes not extend across recesses282fand is out of engagement with anchor “S”. In particular, when in the first position,knife edge294dofknife blade294 is located proximal of recess282f.

As seen inFIG. 39,knife blade294 has a second position in whichknife edge294dextends across a recess282fand is in engagement with anchor “S”. In particular, when in the second position,knife edge294dofknife blade294 includes a portion extending or disposed beyond recess282f.

In operation, during firing ofsurgical stapling apparatus10, as drive assembly50 (seeFIG. 2) is advanced (i.e., moved from a proximal-most position to a distal-most position),drive assembly50 causesknife blade294 to slice through anchor “S”, thereby freeing the distal end of the cartridge buttress “B”. In particular, withknife blade294 in the first position, as seen inFIG. 38, asdrive assembly50 is advanced distally, drive assembly50 contacts or engagescamming edge294cofknife blade294, as indicated by arrow “A”. Asdrive assembly50 is further advanced distally, driveassembly50 creates a moment aroundpivot point283acausingknife blade294 to rotate thereabout, as indicated by arrow “B”. In so doing, as seen inFIG. 39,knife edge294dofknife blade294 is advanced or rotated through anchor “S” thus severing anchor “S” and freeing the distal end of the cartridge buttress “B”.

Turning now toFIGS. 40-42, an anvil assembly according to yet another embodiment of the present disclosure, for use in a DLU of a surgical stapling apparatus, is generally designated as320.Anvil assembly320 is substantially similar toanvil assembly220 and thus will only be discussed herein to the extent necessary to identify differences in construction and operation thereof.

As seen inFIGS. 40-42,anvil assembly320 includes aknife blade374 pivotally secured thereto, in particular, near a distal end thereof.Knife blade374 is positioned so as to rotate about a pivot point to sever anchor “S” as drive assembly50 (seeFIG. 2) is advanced to a distal-most position inanvil assembly320.

In particular, with continued reference toFIGS. 40-42,anvil assembly320 includes apivot point376bformed indistal cap376, in cover plate (not shown) and/or inanvil plate370 for pivotally engaging or supportingknife blade374.Knife blade374 includes alobe374adefining apivot window374bconfigured and dimensioned to pivotally engagepivot point376b.Pivot point376bandpivot window374bdefine a pivot axis “Y” that is spaced a distance from a longitudinal axis “X” oflongitudinal slot370bofanvil plate370.

Knife blade374 defines acamming edge374cextending acrosslongitudinal slot370bofanvil plate370, and aknife edge374dextending transverse tocamming edge374c.Knife blade374 is configured and dimensioned such thatcamming edge374cis disposed proximally of anchor “S” and a portion ofknife edge374dextends across anchor “S”.

As seen inFIGS. 40 and 41,knife blade374 has a first position in whichknife edge374ddoes not extend acrossrecesses370eand is out of engagement with anchor “S”. In particular, when in the first position,knife edge374dofknife blade374 includes a portion extending proximally ofrecesses370e. Also, when in the first position,camming edge374cofknife blade374 is disposed or located proximally ofrecesses370e.

As seen inFIG. 42,knife blade374 has a second position in whichknife edge374dextends across arecess370eand is in engagement with anchor “S”. In particular, when in the second position,knife edge374dofknife blade374 includes a portion extending or disposed beyondrecess370e.

In operation, during firing ofsurgical stapling apparatus10, as drive assembly50 (seeFIG. 2) is advanced (i.e., moved from a proximal-most position to a distal-most position),drive assembly50 causesknife blade374 to slice through anchor “S”, thereby freeing the distal end of the anvil buttress (seeFIG. 2). In particular, withknife blade374 in the first position, as seen inFIG. 41, asdrive assembly50 is advanced distally, drive assembly50 contacts or engagescamming edge374cofknife blade374, as indicated by arrow “A”. Asdrive assembly50 is further advanced distally, driveassembly50 creates a moment aroundpivot point376bcausingknife blade374 to rotate thereabout, as indicated by arrow “B”. In so doing, as seen inFIG. 42,knife edge374dofknife blade374 is advanced or rotated through anchor “S” thus severing anchor “S” and freeing the distal end of the anvil buttress (seeFIG. 2).

Turning now toFIGS. 43-45, a cartridge assembly according to another embodiment of the present disclosure, for use in a DLU of a surgical stapling apparatus, is generally designated as318.Cartridge assembly318 is substantially similar tocartridge assembly218 and thus will only be discussed herein to the extent necessary to identify differences in construction and operation thereof.

As seen inFIGS. 43-45,cartridge assembly318 includes aknife blade394 pivotally secured thereto, in particular, near a distal end thereof.Knife blade394 is positioned so as to rotate about a pivot point to sever anchor “S” as drive assembly50 (seeFIG. 2) is advanced to a distal-most position incartridge assembly318.

In particular, with continued reference toFIGS. 43-45,cartridge assembly318 includes apivot point383aformed in knife blade insert383 and/orstaple cartridge382 for pivotally engaging or supportingknife blade394.Knife blade394 includes alobe394adefining apivot window394bconfigured and dimensioned to pivotally engagepivot point383a.Pivot point383aandpivot window394bdefine a pivot axis “Y” that is spaced a distance from a longitudinal axis “X” of longitudinal slot382cofstaple cartridge382.

Knife blade394 defines a back orcamming edge394cextending across longitudinal slot382cofstaple cartridge382, and aknife edge394dextending parallel tocamming edge394c.Knife blade394 is configured and dimensioned such thatcamming edge394candknife edge394dare located proximal of anchor “S”.

As seen inFIGS. 43 and 44,knife blade394 has a first position in whichknife edge394ddoes not extend acrossrecesses382fand is out of engagement with anchor “S”. In particular, when in the first position,knife edge394dofknife blade394 is located proximal ofrecess382f.

As seen inFIG. 45,knife blade394 has a second position in whichknife edge394dextends across arecess382fand is in engagement with anchor “S”. In particular, when in the second position,knife edge394dofknife blade394 includes a portion extending or disposed beyondrecess382f.

In operation, during firing ofsurgical stapling apparatus10, as drive assembly50 (seeFIG. 2) is advanced (i.e., moved from a proximal-most position to a distal-most position),drive assembly50 pushesactuation sled90 intoknife blade394 causingknife blade394 to slice through anchor “S”, thereby freeing the distal end of the cartridge buttress “B”. In particular, withknife blade394 in the first position, as seen inFIG. 44, asdrive assembly50 is advanced distally, driveassembly50 movedactuation sled90 into contact or engagement withcamming edge394cofknife blade394, as indicated by arrow “A”. Asdrive assembly50 is further advanced distally,actuation sled90 creates a moment aroundpivot point383acausingknife blade394 to rotate thereabout, as indicated by arrow “B”. In so doing, as seen inFIG. 45,knife edge394dofknife blade394 is advanced or rotated through anchor “S” thus severing anchor “S” and freeing the distal end of the cartridge buttress “B”.

Turning now toFIG. 46, an anvil assembly according to yet another embodiment of the present disclosure, for use in a DLU of a surgical stapling apparatus, is generally designated as420.Anvil assembly420 is substantially similar toanvil assemblies220 and320 and thus will only be discussed herein to the extent necessary to identify differences in construction and operation thereof.

As seen inFIG. 46,anvil assembly420 includes aknife blade474 pivotally secured thereto, in particular, near a distal end thereof.Knife blade474 is positioned so as to rotate about a pivot point to sever anchor “S” as drive assembly50 (seeFIG. 2) is advanced to a distal-most position inanvil assembly420.

In particular, with continued reference toFIG. 46,anvil assembly420 includes apivot point476bformed indistal cap476, in the cover plate (not shown) and/or inanvil plate470 for pivotally engaging or supportingknife blade474.Knife blade474 includes alobe474adefining apivot window474bconfigured and dimensioned to pivotally engagepivot point476b.Pivot point476bandpivot window474bdefine a pivot axis “Y” that is spaced a distance from a longitudinal axis “X” of longitudinal slot470bofanvil plate470.

Knife blade474 defines acamming edge474cextending across longitudinal slot470bofanvil plate470, and aknife edge474dextending transverse tocamming edge474c.Knife blade474 is configured and dimensioned such thatcamming edge474cis disposed proximally of the anchor (not shown) and a portion ofknife edge474dextends across anchor.

As seen inFIG. 46,knife blade474 has a first position in whichknife edge474ddoes not extend acrossrecesses470eand is out of engagement with anchor. In particular, when in the first position,knife edge474dofknife blade474 includes a portion extending proximally ofrecesses470eand a portion extending distally ofrecesses470e. Also, when in the first position,camming edge474cofknife blade474 is disposed or located proximally ofrecesses470e.

Turning now toFIGS. 47-75, an end effector, configured for use or connection with a handle of an endoscopic surgical stapling apparatus is generally designated as1000.End effector1000 includes acartridge assembly1200 housing a plurality of surgical fasteners or staples1228 (seeFIG. 48) and ananvil assembly1300 movably secured in relation tocartridge assembly1200.End effector1000 measures from about 30 mm to about 60 mm in length.End effector1000 may be configured to apply six (6) linear rows of staples.

As seen inFIGS. 47-49,end effector1000 is configured as a disposable loading unit configured for selective connection with a handle assembly (not shown).

As seen inFIG. 49,end effector1000 includes anaxial drive assembly1150 operatively associated with and slidably disposed betweencartridge assembly1200 andanvil assembly1300.Axial drive assembly1150 includes anelongated drive beam1152 having adistal end1152aand aproximal end1152b.Drive beam1152 is constructed from multiple stacked beams.

Proximal end1152bofdrive beam1152 is formed as a pair of resilient engagement fingers which are dimensioned and configured to mountingly engage a drive or control rod (not shown) when the proximal end ofend effector1000 is connected to the handle assembly.

Distal end1152aofdrive beam1152 is configured as an I-beam including an upper andlower rail portion1154a,1154b, respectively, extending transversely therefrom. A distal edge of a central beam ofdrive beam1152 defines aknife blade1156.

As seen inFIGS. 49-62,cartridge assembly1200 includes acarrier1210 defining anelongated support channel1212.Elongated support channel1212 ofcarrier1210 is dimensioned and configured to selectively receive astaple cartridge1220 therein. Corresponding tabs and slots formed alongstaple cartridge1220 andcarrier1210 function to retainstaple cartridge1220 withincarrier1210.Staple cartridge1220 includesretention slots1222 formed therein for receiving a plurality of surgical staples1224 andpushers1226.

As seen inFIGS. 49,50,53 and55,cartridge assembly1200 further includes anactuation sled1228 slidably disposed betweenstaple cartridge1220 andcarrier1210.Actuation sled1228 includes a central upstanding wedge orwall1228aflanked by a pair of outer cam wedges orwalls1228b.Central wall1228adefines a distal notch orshoulder1228cformed therein.

As seen inFIGS. 49 and 60, a centrallongitudinal slot1234 is formed in and extends along the length ofstaple cartridge1220 to enable passage ofdrive beam1152 therethrough. During operation of the surgical stapler,actuation sled1228 translates alongstaple cartridge1220 andcarrier1210 to advanceouter cam wedges1228binto sequential contact withpushers1226, to causepushers1226 to translate vertically withinretention slots1222 and urge staples1224 fromslots1222 into thestaple forming cavities1312 ofanvil plate1310 of anvil assembly1300 (seeFIG. 66).

With reference toFIGS. 56-59,staple cartridge1220 defines a proximal pair ofrecesses1236 formed near a proximal end thereof and disposed, one each, on opposed sides oflongitudinal slot1234.Staple cartridge1220 further defines a distal pair ofrecesses1238 formed near a distal end thereof and disposed, one each, on opposed sides oflongitudinal slot1234. As seen inFIGS. 57-59, at least one recess of each of the proximal pair ofrecesses1236 and the distal pair ofrecesses1238 is in the form of a slot or notch having a constricting profile so as to frictionally engage and/or pinch a suture “S”.

As seen inFIGS. 49,53,54,57 and60-62,cartridge assembly1200 further includes aknife blade1240 defining a distally orientedknife edge1242 and being pivotally supported instaple cartridge1220.Knife blade1240 has an initial or first condition whereinknife edge1242 is positioned proximal of one of the distal pair ofrecesses1238 and a final or second condition whereinknife edge1242 is positioned distal of the one of the distal pair ofrecesses1238.

Cartridge assembly1200 includes aknife blade housing1246 supported instaple cartridge1220 at a location associated with the distal pair ofrecesses1238. As seen inFIG. 61,knife blade housing1246 includes ahub1246aonto whichknife blade1240 is rotatably connected.

As seen inFIGS. 49,51,52 and54-59,cartridge assembly1200 further includes a surgical cartridge buttress “B1” operatively secured to an upper surface ofstaple cartridge1220, by sutures “S”, to overlie at least some ofretention slots1222 and/or at least a portion of a length oflongitudinal slot1234. Surgical cartridge buttress “B1” includes a proximal end portion in the form of tongue “B1a” having a transverse width dimension which is less than a transverse width dimension of surgical cartridge buttress “B1”, and a distal end portion in the form of tongue “B1b” having a transverse width dimension which is less than the transverse width dimension of surgical cartridge buttress “B1”. The proximal end portion “B1a” of surgical cartridge buttress “B1” defines a pair of apertures “B1c” formed therein for receivingposts1252 ofstaple cartridge1220 therein. A first suture “S1” is threaded through each of the distal pair ofrecesses1238 and around/over distal tongue “B1b” of cartridge buttress “B1” and, and a second suture “S2” is threaded through each of the proximal pair ofrecesses1236 and around/over proximal tongue “B1a” of cartridge buttress “B1”.

A first end of each suture “S1, S2” is anchored or fixed in a respective one recesses of the proximal and distal pair ofrecesses1236,1238 while a second end of each suture “S1, S2” passes transversely across respective distal and proximal tongues “B1b, B1a” of cartridge buttress “B1” and is anchored or fixed in a respective other recess of the proximal and distal pair ofrecesses1236,1238.

As seen inFIGS. 49,56 and58,staple cartridge1220 includes a pair of spaced apart posts1252 disposed on opposed sides oflongitudinal slot1234.Posts1252 are located distal of and adjacent to proximal suture “S2”.Posts1252 are received in openings formed in cartridge buttress “B1”.Posts1252 function to maintain the position of cartridge buttress “B1” relative tostaple cartridge1220 asdrive assembly1150 is moved distally.Posts1252 also function to brace proximal sutures “S2” asdrive assembly1150 is moved distally.

As seen inFIGS. 49,51-55 and63-67,anvil assembly1300 includes ananvil plate1310 having a plurality of staple deforming pockets/cavities1312 (seeFIG. 66) and acover plate1320 secured to a top surface ofanvil plate1310, wherein acavity1313 is defined therebetween. The cavity defined betweenanvil plate1310 andcover plate1320 is dimensioned to slidably receiveupper rail portion1154aofdrive beam1152 therein. Alongitudinal slot1314 extends throughanvil plate1310 to facilitate passage ofdrive beam1152 therethrough.

In operation, an upper surface ofanvil plate1310 defines a camming surface1310aagainst whichupper rail portion1154aofdrive beam1152 engages to cam, urge and clampanvil assembly1300 against the tissue asdrive assembly1150 advances drivebeam1152 throughlongitudinal slot1314.

With continued reference toFIGS. 49,51,52 and63-67,anvil plate1310 defines a proximal pair ofrecesses1316 formed near a proximal end ofanvil plate1310 and disposed, one each, on opposed sides oflongitudinal slot1314.Anvil plate1310 defines a distal pair ofrecesses1318 formed near a distal end ofanvil plate1310 and disposed, one each, on opposed sides oflongitudinal slot1314. At least one recess of each of the proximal pair ofrecesses1316 and the distal pair ofrecesses1318 is in the form of a slot or notch having a constricting profile so as to frictionally engage and/or pinch a suture “S”.

As seen inFIGS. 49,51-54 and64-67,anvil assembly1300 further includes aknife blade1330 defining a distally orientedknife edge1332 and being pivotably interposed within the cavity defined betweenanvil plate1310 andcover plate1320.Knife blade1330 has an initial or first condition whereinknife edge1332 is positioned proximal of one of the distal pair ofrecesses1318 and a final or second condition whereinknife edge1332 is positioned distal of the one of the distal pair ofrecesses1318.

As seen inFIGS. 49,51-54 and64-67,anvil assembly1300 includes aknife blade housing1336 supported betweenanvil plate1310 andcover plate1320 at a location associated with the distal pair ofrecesses1318. As seen inFIGS. 64 and 67,knife blade housing1336 includes ahub1336aonto whichknife blade1330 is rotatably connected.

Anvil assembly1300 further includes a surgical anvil buttress “B2” operatively secured to a lower surface ofanvil plate1310, by sutures “S”, to overlie at least some of anvil pockets1312aand/or at least a portion of a length oflongitudinal slot1314. Surgical anvil buttress “B2” includes a proximal end portion in the form of tongue “B2a” having a transverse width dimension which is less than a transverse width dimension of surgical anvil buttress “B2”, and a distal end portion in the form of tongue “B2b” having a transverse width dimension which is less than the transverse width dimension of surgical anvil buttress “B2”. A first suture “S3” is threaded through each of the distal pair ofrecesses1318, and a second suture “S4” is threaded through each of the proximal pair ofrecesses1316.

A first end of suture “S3” is anchored or fixed in a recess of the distal pair ofrecesses1318 and a second end of suture “S3” passes around/over distal tongue “B2b” of anvil buttress “B2”, transversely thereacross anvil buttress “B2”, so as to be anchored or fixed in the other recess of the distal pair ofrecesses1318.

A first end of suture “S4” is anchored or fixed in a recess of the proximal pair ofrecesses1316 while a second end of suture “S4” passes around/over proximal tongue “B2a” of anvil buttress “B2” and is anchored or fixed in the other recess of the proximal and pair ofrecesses1316.

As seen inFIGS. 47-49,51,63 and65-67,cover plate1320 ofanvil assembly1300 includes a pair of walls1322 extending in a direction ofanvil plate1310. Walls1322 are formed near a proximal end ofcover plate1320 and extend from opposed side edges thereof. Walls1322 are configured such that whencartridge assembly1200 andanvil assembly1300 are in a closed or clamped condition, walls1322 extends across a tissue gap defined therebetween. Walls1322 function as tissue stops, inhibiting tissue flow in a proximal direction during a clamping or closing ofend effector1000.

In operation, as seen inFIGS. 68-72, with anvil buttress “B2” secured against the lower surface ofanvil plate1310, during firing of the surgical stapling apparatus, asdrive assembly1150 is advanced (e.g., moved from a proximal-most position to a distal-most position),knife blade1156 slices through a central section of suture “S4”, thereby freeing the proximal end of anvil buttress “B2” fromanvil assembly1300. Asdrive assembly1150 approaches the distal end ofanvil assembly1300,upper rail portion1154aofdrive beam1152 abuts against and urgesknife blade1330 to rotate distally. Asknife blade1330 is rotated distally,knife edge1332 is rotated from the initial or first condition positioned proximal of one of the distal pair ofrecesses1318 to the final or second condition positioned distal of the one of the distal pair ofrecesses1318. In so doing,knife edge1332 slices or cuts through suture “S3”, thereby freeing the distal end of the anvil buttress “B2” fromanvil assembly1300.

Concomitantly therewith, in operation, as seen inFIGS. 68-75, with cartridge buttress “B1” secured against the tissue contacting surface ofstaple cartridge1220, during firing of the surgical stapling apparatus, asdrive assembly1150 is advanced (e.g., moved from a proximal-most position to a distal-most position),knife blade1156 slices through a central section of the proximal suture “S2”, thereby freeing the proximal end of the cartridge buttress “B1” fromcartridge assembly1200.

Asdrive assembly1150 approaches the distal end ofstaple cartridge1220,shoulder1228cof central upstanding wedge orwall1228aofactuation sled1228 abuts against and urgesknife blade1240 to rotate distally. Asknife blade1240 is rotated distally,knife edge1242 is rotated from the initial or first condition positioned proximal of one of the distal pair ofrecesses1238 to the final or second condition positioned distal of the one of the distal pair ofrecesses1238. In so doing,knife edge1242 slices or cuts through distal suture “S1”, thereby freeing the distal end of the cartridge buttress “B1” fromcartridge assembly1200.

Asdrive assembly1150 is advanced from a proximal-most position to a distal-most position,knife blade1156 thereof slices or cuts longitudinally through both cartridge buttress “B1” and anvil buttress “B”, thereby dividing the buttresses “B1, B2” substantially in half. Additionally, asdrive assembly1150 is advanced from a proximal-most position to a distal-most position,upstanding cam wedges1228bofactuation sled1228 actuatespushers1226, to causepushers1226 to translate vertically withinretention slots1222 and urge staples1224 fromslots1222. As staples1224 are urged fromslots1222 ofstaple cartridge1220, legs of staples1224 penetrate and pass through both cartridge buttress “B1” and anvil buttress “B2”, through any tissue (not shown) interposed between cartridge buttress “B1” and anvil buttress “B2”, and are formed against or withinstaple deforming pockets1312 ofanvil plate1310 ofanvil assembly1300.

Surgical buttresses “B1, B2” are each fabricated from a suitable biocompatible and bioabsorbable material. Surgical buttresses “B1, B2” are each fabricated from a non-absorbent material which does not retain fluid. Surgical buttresses “B1, B2” are each fabricated from “BIOSYN” made from GLYCOMER631 (a block copolymer), a synthetic polyester composed of glycolide, dioxanone and trimethylene carbonate.

One block of the resulting copolymer contains randomly combined units derived from p-dioxanone(1,4-dioxan-2-one) and trimethylene carbonate(1,3-dioxan-2-one). The second block of the copolymer contains randomly combined units derived from glycolide and p-dioxanone. The resulting polyester is an ABA triblock terpolymer possessing about 60% glycolide, about 14% dioxanone, and about 26% trimethylene carbonate.

End effector1000 is shown inFIGS. 47 and 48 as being capable of articulation about a pivot point.Cartridge assembly1200 andanvil assembly1300 may form a part of a non-articulating SULU.

Turning now toFIGS. 76 and 77, a surgical cartridge buttress “B1,” according to another embodiment of the present disclosure, is shown operatively secured to a tissue side of thestaple cartridge220. The surgical cartridge buttress “B1” includes a proximal end portion “B1b,” in the form of a tongue, having a transverse width dimension that is less than a transverse width dimension of a central body portion “B1a” of the surgical cartridge buttress “B1;” and a distal end portion “B1c,” in the form of a tongue, also having a transverse width dimension that is less than the transverse width dimension of central body portion “B1a” of surgical cartridge buttress “B1.”

The proximal tongue “B1b” of surgical cartridge buttress “B1” ofFIGS. 76 and 77 defines a pair of lateral notches “B1d, B1e” formed in a rear edge thereof, and a central notch “B1f” formed in a rear edge thereof between lateral notches “B1d. B1e” and located along a center line of surgical cartridge buttress “B1.” Lateral notches “B1d, B1e” are sized to receiveposts252 projecting from ofstaple cartridge220. Central notch “B1f” has a triangular or V-shape configuration for providing a lead in for the knife during a cutting of surgical cartridge buttress “B1.”

Surgical cartridge buttress “B1” ofFIGS. 76 and 77 further includes a pair of lateral recesses “B1h, B1i” formed in the lateral side edges of body portion “B1a,” near a proximal end thereof; and a pair of lateral recesses “B1j, B1k” formed in the lateral side edges of body portion “B1a,” near a distal end thereof. Each recess is substantially triangular in shape and is dimensioned to extend beyond the respective proximal and distal pair ofrecesses236,238 ofstaple cartridge220.

As seen inFIGS. 78-80,staple cartridge220 defines a centrallongitudinal slot234, and a plurality of rows ofstaple retention slots222 formed on either side of centrallongitudinal slot234.Staple cartridge220 includes a pair ofproximal pads220a,220bprojecting from an upper surface thereof.Pads220a,220bare disposed on opposite sides oflongitudinal slot234, near a proximal end thereof.Staple cartridge220 further includes adistal pad220cprojecting from an upper surface thereof.Pad220cis disposed distally oflongitudinal slot234. In use,pads220a-220cenhance a gripping effect between surgical cartridge buttress “B1” andstaple cartridge220 when surgical cartridge buttress “B1” is cinched thereto by the sutures.

Turning now toFIG. 81, a surgical anvil buttress “B2” according to another embodiment of the present disclosure is shown operatively secured to a tissue side of theanvil plate310 ofanvil assembly300. The surgical anvil buttress “B2” ofFIG. 81 includes a proximal end portion “B2b,” in the form of a tongue, having a transverse width dimension that is less than a transverse width dimension of a central body portion “B2a” of the surgical anvil buttress “B2;” and a distal end portion “B2c,” in the form of a tongue, also having a transverse width dimension that is less than the transverse width dimension of central body portion “B2a” of surgical anvil buttress “B2.”

As seen inFIG. 82, proximal tongue “B2b” of surgical anvil buttress “B2” defines a central notch “B2f” formed in a rear edge thereof and located along a center line of surgical anvil buttress “B2.” Central notch “B2f” has a triangular or V-shape.

Surgical anvil buttress “B2” as seen inFIG. 82 further includes a pair of lateral recesses “B2h, B2i” formed in the lateral side edges of body portion “B2a,” near a proximal end thereof; and a pair of lateral recesses “B2j, B2k” formed in the lateral side edges of body portion “B2a,” near a distal end thereof. Each recess is substantially triangular in shape and is dimensioned to extend beyond the respective proximal and distal pair ofrecesses316,318 ofanvil plate310 ofanvil assembly300.

As seen inFIGS. 82-84A,anvil knife blade330 may be configured to include a distally oriented, double-beveled,knife edge332 having a concave profile.Anvil knife blade330 includes a distally extending finger ortooth330aformed at a free end thereof.

Anvil knife blade330 defines a substantiallycircular aperture330b, including a flattenedportion330c, formed in an end thereof.Aperture330bis configured to receive ahub336aof aknife blade housing336 including a complementarily shaped flattenedportion336b. In use, flattenedportion330cofanvil knife blade330 mates with the complementary flattenedportion336bofhub336ato help maintain the relative orientation ofanvil knife blade330 prior to an actuation by the drive assembly.

As seen inFIGS. 82-84,knife blade housing336 includes a pair of extensions or legs, for a 12 mm DLU or SULU, and only a single leg or extension (seeFIG. 86), for a 15 mm DLU or SULU.

As seen inFIG. 85,cartridge carrier210 may include alongitudinally extending slot210aterminating in an enlargeddistal end210b.Distal end210bhas a transverse width dimension that is greater than a transverse width dimension ofslot210a. The width dimension ofdistal end210bhas been enlarged to make sure the drive bar stops on a flat surface as compared to a full round configuration and provides more control of overall stroke of the drive bar.

As seen inFIGS. 76 and 78,staple cartridge220 defines a distal pair of recesses, formed in side edges thereof, for receiving a suture therein, wherein each recess is a constricting slot for cinched receipt of the suture. As seen inFIG. 81,anvil assembly300 andanvil plate310 define a distal pair ofrecesses318, formed in side edges thereof, for receiving a suture therein, wherein eachrecess318 is a constricting slot for cinched receipt of the suture.

As seen inFIGS. 86 and 87,anvil knife blade330 is supported onknife blade housing336, for either a 12 mm DLU/SULU or a 15 mm DLU/SULU, in a biased manner. In particular, aresilient member331 is interposed betweenanvil knife blade330 and a surface ofknife blade housing336 in such a manner so as to maintainanvil knife blade330 in a first position disposed proximal of the suture or either of the distal pair of suture receiving recesses thereof prior to any firing of the surgical instrument. As seen inFIGS. 86 and 87,resilient member331 may be in the form of a leaf spring including a first end connected toanvil knife blade330 and a second end in contact with a surface ofknife blade housing336. In operation, as drive assembly50 (seeFIG. 2) is driven distally, theupper rail64aof I-beam60 (see for exampleFIGS. 4 and 5) abuts against and urgesanvil knife blade330 distally (“A”), thus rotatinganvil knife blade300 across the suture to sever the suture, and thereby releasing a distal end of the surgical anvil buttress. In doing so,leaf spring331 is biased or deflected.

In an alternate embodiment, as seen inFIG. 90, aresilient member331 a may be in the form of a coil spring including afirst leg331bin contact with a surface ofknife blade housing336, asecond leg331cin contact with asurface330bofanvil knife blade330, and acoil portion331dpositioned onhub336aofknife blade housing336 and interconnectingfirst leg331bandsecond leg331c.

In accordance with the present disclosure, it is further envisioned and contemplated that at least one of surgical cartridge buttress “B1” and surgical anvil buttress “B2” may be at least partially opaque, translucent and/or transparent. In this manner, the user may be able to better view the staple line following a firing of the surgical instrument. It is further envisioned that at least one of surgical cartridge buttress “B1” and surgical anvil buttress “B2” may be photo-luminescent, dyed and/or photoresponsive/photoreactive (i.e., able to change colors) in the presence of blood or the like.

While the above-described embodiments surgical staplers incorporating the use of movable knife blades to sever and release surgical buttresses from the tissue contacting surfaces of the anvil assembly and the cartridge assembly have been shown and described in relation to endoscopic surgical staplers, it is envisioned and within the scope of the present disclosure that any of the above-embodiments may be incorporated into any type of surgical stapler, including and not limited to open surgical staplers, such as, for example, linear surgical staplers; arcuate or annular surgical staplers; and transverse surgical staplers.

It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the stapling apparatus need not apply staples but rather may apply two part fasteners as is known in the art. Further, the length of the linear row of staples or fasteners may be modified to meet the requirements of a particular surgical procedure. Thus, the length of a single stroke of the actuation shaft and/or the length of the linear row of staples and/or fasteners within a disposable loading unit may be varied accordingly. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.

Claims (20)

1. A surgical apparatus of the type including a handle assembly operable with a drive assembly to eject at least one staple from the surgical apparatus, the surgical apparatus comprising:

a cartridge assembly defining a tissue contacting surface and a longitudinally extending elongate slot;

an anvil assembly defining a tissue contacting surface and a longitudinally extending elongate slot; and

a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor, and

an axial drive assembly movable for firing surgical staples from the cartridge assembly, wherein the axial drive assembly has a central knife blade slidably disposable in the longitudinally extending elongate slot of the cartridge assembly and the anvil assembly, the central knife blade being received in a notch of the surgical buttress upon an advancement of the central knife blade through the longitudinal extending slot;

wherein at least one of the cartridge assembly and the anvil assembly including:

a pair of recesses formed in a respective side edge thereof,

wherein the anchor extends across the pair of recesses of the at least one of the cartridge assembly and the anvil assembly for securing the surgical buttress thereto,

an other knife blade pivotably mounted on the at least one of the cartridge assembly and the anvil assembly, the other knife blade having a distally oriented knife edge and being movable from a position proximal of the pair of recesses to a position distal of the pair of recesses, the other knife blade being movable to cut the anchor.

2. The surgical apparatus according toclaim 1, wherein each of the cartridge assembly and the anvil assembly includes:

a distal pair of recesses formed in a respective side edge thereof; and

a proximal pair of recesses formed in a respective side edge thereof; and

wherein a suture extends across respective distal and proximal pairs of recesses of the cartridge assembly and the anvil assembly for securing a respective surgical buttress thereto.

3. The Surgical apparatus according toclaim 2, wherein a knife blade is supported in a distal end portion of each of the cartridge assembly and the anvil assembly.

4. The surgical apparatus according toclaim 1, wherein the axial drive assembly moves the knife blade from the position proximal of the pair of recesses to the position distal of the pair of recesses.

5. The surgical apparatus according toclaim 1, wherein the anchor is a suture.

6. The surgical apparatus according toclaim 1, wherein the surgical buttress is pre-loaded onto the at least one of the cartridge assembly and the anvil assembly by the manufacturer before use.

7. A surgical apparatus of the type including a handle assembly operable with a drive assembly to eject at least one staple from the surgical apparatus, the surgical apparatus comprising:

a cartridge assembly defining a tissue contacting surface and a longitudinally extending elongate slot;

an anvil assembly defining a tissue contacting surface and a longitudinally extending elongate slot;

wherein each of the cartridge assembly and the anvil assembly includes:

a distal pair of recesses formed in a respective side edge thereof; and

a proximal pair of recesses formed in a respective side edge thereof; and

wherein a suture extends across respective distal and proximal pairs of recesses of the cartridge assembly and the anvil assembly for securing a respective surgical buttress thereto; and

a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor, wherein

at least one of the cartridge assembly and the anvil assembly including:

a pair of recesses formed in a respective side edge thereof, wherein the anchor extends from one of the pair of recesses to the other of the pair of recesses for securing the surgical buttress thereto,

a knife blade pivotably mounted on the at least one of the cartridge assembly and the anvil assembly, the knife blade having a distally oriented knife edge and being movable from a position proximal of the pair of recesses to a position distal of the pair of recesses upon an actuation of the axial drive assembly, the knife being movable to cut the anchor.

8. The surgical apparatus according toclaim 7, further comprising an axial drive assembly movable for firing surgical staples from the cartridge assembly.

9. The surgical apparatus according toclaim 8, wherein the axial drive assembly has a central knife blade slidably disposable in the longitudinal extending elongate slot of the cartridge assembly and the anvil assembly.

10. The surgical apparatus according toclaim 7, wherein a knife blade is supported in a distal end portion of each of the cartridge assembly and the anvil assembly.

11. The surgical apparatus according toclaim 8, wherein the axial drive assembly moves the knife blade from the position proximal of the pair of recesses to the position distal of the pair of recesses.

12. The surgical apparatus according toclaim 7, wherein the anchor is a suture.

13. The surgical apparatus according toclaim 7, wherein the surgical buttress is pre-loaded onto the at least one of the cartridge assembly and the anvil assembly by the manufacturer before use.

14. A surgical apparatus of the type including a handle assembly operable with a drive assembly to eject at least one staple from the surgical apparatus, the surgical apparatus comprising:

a cartridge assembly defining a tissue contacting surface and a longitudinally extending elongate slot;

an anvil assembly defining a tissue contacting surface and a longitudinally extending elongate slot;

a surgical buttress releasably secured to at least one of the tissue contacting surface of the cartridge assembly and the tissue contacting surface of the anvil assembly by at least one anchor, the anchor being a suture,

at least one of the cartridge assembly and the anvil assembly including:

a pair of recesses formed in a respective side edge thereof,

wherein the anchor extends across the pair of recesses of the at least one of the cartridge assembly and the anvil assembly for securing the surgical buttress thereto,

a knife blade pivotably mounted on the at least one of the cartridge assembly and the anvil assembly, the knife blade having a distally oriented knife edge and being movable from a position proximal of the pair of recesses to a position distal of the pair of recesses upon an actuation of the axial drive assembly, the knife being movable to cut the anchor.

15. The surgical apparatus according toclaim 14, further comprising an axial drive assembly movable for firing surgical staples from the cartridge assembly.

16. The surgical apparatus according toclaim 15, wherein the axial drive assembly has a central knife blade slidably disposable in the longitudinal extending elongate slot of the cartridge assembly and the anvil assembly.

17. The surgical apparatus according toclaim 15, wherein the axial drive assembly moves the knife blade from the position proximal of the pair of recesses to the position distal of the pair of recesses.

18. The surgical apparatus according toclaim 14, wherein each of the cartridge assembly and the anvil assembly includes:

a distal pair of recesses formed in a respective side edge thereof; and

a proximal pair of recesses formed in a respective side edge thereof; and

wherein a suture extends across respective distal and proximal pairs of recesses of the cartridge assembly and the anvil assembly for securing a respective surgical buttress thereto.

19. The surgical apparatus according toclaim 18, wherein a knife blade is supported in a distal end portion of each of the cartridge assembly and the anvil assembly.

20. The surgical apparatus according toclaim 14, wherein the surgical buttress is pre-loaded onto the at least one of the cartridge assembly and the anvil assembly by the manufacturer before use.

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